Miller 242780 Owner's manual

Brand: Miller

Model: 242780

Category: Welding System

Type: Owner's manual

This manual is also suitable for

XMS 44

Processes

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Wire Feeder

OM-223 839D 2010−02

XMS 44

Wire Feeder

OWNER’S MANUAL

Visit our website at

www.MillerWelds.com

Thank you and congratulations on choosing Miller. Now you can get the

job done and get it done right. We know you don’t have time to do it any

other way.

That’s why when Niels Miller first started building arc welders in 1929,

he made sure his products offered long-lasting value and superior quality.

Like you, his customers couldn’t afford anything less. Miller products had

to be more than the best they could be. They had to be the best you could

buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They will

help you protect yourself against potential hazards on the worksite. We’ve

made installation and operation quick and easy. With Miller you can

count on years of reliable service with proper maintenance. And if for

some reason the unit needs repair, there’s a Troubleshooting section that

will help you figure out what the problem is. The parts list will then help

you to decide which exact part you may need to fix the problem.

Warranty and service information for your particular model are also

provided.

Miller Electric manufactures a full line of

welders and welding related equipment. For

information on other quality Miller products, contact your local Miller

distributor to receive the latest full line catalog or individual catalog sheets.

Working as hard as you do

− every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1...................................

1-1. Symbol Usage 1........................................................................

1-2. Arc Welding Hazards 1..................................................................

1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................

1-4. California Proposition 65 Warnings 4.......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4......................................................................

SECTION 2 − DEFINITIONS 5...................................................................

2-1. Manufacturer’s Warning Label Definitions 5.................................................

2-2. Symbols And Definitions 6...............................................................

SECTION 3 − INTRODUCTION 7.................................................................

3-1. Important Information Regarding CE Products (Sold Within The EU) 7...........................

3-2. Serial Number And Rating Label Location 7.................................................

3-3. Specifications 7........................................................................

3-4. Remote 7 Receptacle Information 7........................................................

3-5. 14-Pin Plug Information 8................................................................

3-6. Connecting Welding Gun 9...............................................................

3-7. Installing Wire Guide And Drive Roll 9......................................................

3-8. Circuit Protection 10.....................................................................

3-9. Connecting Wire Feeder to Power Source 10.................................................

3-10. Changing Cable Between Wire Feeder and XMS 403 11.......................................

3-11. Installing Wheels On Wire Feeder (Optional) 11...............................................

SECTION 4 − OPERATION 12....................................................................

4-1. Control Panel 12.........................................................................

4-2. Switching On Unit And Recalling Factory Parameters 13.......................................

4-3. Welding Process Selection 13.............................................................

4-4. Trigger Mode Selection 14................................................................

4-5. Setup Menu and Memory Menu Selection 14.................................................

4-6. Setup Menu 15..........................................................................

4-7. Memory Menu 15........................................................................

4-8. Jog And Purge Selection 15...............................................................

4-9. Preparing Unit For MIG Welding 16.........................................................

4-10. Selecting Manual MIG Welding 17..........................................................

4-11. Selecting Synergic MIG Welding 18.........................................................

4-12. Selecting Synergic Pulsed MIG Welding 19..................................................

SECTION 5 − MAINTENANCE & TROUBLESHOOTING 20...........................................

5-1. Routine Maintenance 20..................................................................

5-2. Help Displays 20........................................................................

5-3. Troubleshooting 21......................................................................

SECTION 6 − ELECTRICAL DIAGRAM 23..........................................................

SECTION 7 − PARTS LIST 24.....................................................................

WARRANTY

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares

that the product(s) identified in this declaration conform to the essential requirements and provi

sions of the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

XMS 44 029 007 424

Council Directives:

S 2006/95/EC Low Voltage

S 2004/108/EC Electromagnetic Compatibility

S 2006/42/EEC Machinery Directive

Standards:

S IEC 609741 Arc Welding Equipment  Welding Power Sources: edition 3, 200507.

S IEC 609745 Arc Welding Equipment – Wire Feeders: edition 2, 200711.

S IEC 6097410 Arc Welding Equipment  Electromagnetic Compatibility Requirements: edition 1.1, 200410.

S EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,

arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic

fields (0Hz300Hz)

EU Signatory:

____________________________________________________________

_________________

Mark Lowther

Date of Declaration

EUROPEAN DIRECTOR, TECHNOLOGY & PRODUCT DEVELOPMENT

956 142 701

November 24th, 2009

OM-223 839 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som _2009−08

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE − Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shock

or severe burns. The electrode and work circuit i

electrically live whenever the output is on. The inpu

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automati

wire welding, the wire, wire reel, drive roll housing

and all metal parts touching the welding wire are

electrically live. Incorrectly installed or improperl

grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on

unit.

D Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp

locations or while wearing wet clothing; on metal structures such

as floors, gratings, or scaffolds; when in cramped positions such

as sitting, kneeling, or lying; or when there is a high risk of unavoid-

able or accidental contact with the workpiece or ground. For these

conditions, use the following equipment in order presented: 1) a

semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter weld-

ing power sources AFTER removal of inputpower.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.

D Allow cooling period before working on equip-

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

OM-223 839 Page 2

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

D If ventilation is poor, wear an approved air-supplied respirator.

D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,

coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and while wearing an air-supplied

respirator. The coatings and any metals containing these elements

can give off toxic fumes if welded.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

D Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and

sparks when welding or watching (see ANSI Z49.1 and Z87.1

listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant

material (leather, heavy cotton, or wool) and foot protection.

ARC RAYS can burn eyes and skin.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Do not weld where flying sparks can strike flammable material.

D Protect yourself and others from flying sparks and hot metal.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock, sparks, and fire

hazards.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EM

can affect ImplantedMedical Devices.

D Wearers of Pacemakers and other Implante

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their docto

and the device manufacturer before going near arc welding, spo

welding, gouging, plasma arc cutting, or induction heating

operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder − explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

OM-223 839 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu-

ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper

face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or

servicing unit. Read the safety information at

the beginning of the manual and in each

section.

D Use only genuine replacement parts from the manufacturer.

D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local

codes.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

OM-223 839 Page 4

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases

which contain chemicals known to the State of California to

cause birth defects and, in some cases, cancer. (California

Health & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductive harm. Wash hands after handling.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproduc-

tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth

defects, and other reproductive harm.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:

www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 4221 Walney Road, 5th Floor,

Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-

site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—

phone for Region 5, Chicago, is 312-353-2220, website:

www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East West

Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:

www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na-

tional Institute for Occupational Safety and Health (NIOSH), 1600

Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:

www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric

and magnetic fields (EMF). Welding current creates an EMF field

around the welding circuit and welding equipment. EMF fields may inter-

fere with some medical implants, e.g. pacemakers. Protective

measures for persons wearing medical implants have to be taken. For

example, access restrictions for passers−by or individual risk assess-

ment for welders. All welders should use the following procedures in

order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Do not place your body between welding cables. Arrange cables

to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the

welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire

feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

OM-223 839 Page 5

SECTION 2 − DEFINITIONS

2-1. Manufacturer’s Warning Label Definitions

1 1.1 1.2 1.3

3 3.1 3.2 3.3

4 4.1

2.1

2.2

2.3

S-178 936

1. Warning! Watch Out! There are

possible hazards as shown by the

symbols.

2. Drive rolls can injure fingers

3. Welding wire and drive parts are at

welding voltage during operation −

keep hands and metal objects clear.

1 Electric shock can kill.

1.1 Wear dry insulating gloves. Do not

touch electrode with bare hand. Do

not wear wet or damaged gloves.

1.2 Protect yourself from electric shock by

insulating yourself from work and

ground.

1.3 Disconnect input plug or power before

working on machine.

2 Breathing welding fumes can be

hazardous to your health.

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust

to remove the fumes.

2.3 Use ventilating fan to remove fumes.

3 Welding sparks can cause explosion

or fire.

3.1 Keep flammables away from welding.

Don’t weld near flammables.

3.2 Welding sparks can cause fires. Have

a fire extinguisher nearby and have a

watch person ready to use it.

3.3 Do not weld on drums or any closed

containers.

4 Arc rays can burn eyes and injure

skin.

4.1 Wear hat and safety glasses. Use ear

protection and button shirt collar. Use

welding helmet with correct shade of

filter. Wear complete body protection.

5 Become trained and read the

instructions before working on the

machine or welding.

6 Do not remove or paint over (cover)

the label.

ABC

Do not discard this product with

general waste.

Reuse or recycle Waste Electrical

and Electronic Equipment (WEEE)

by disposing at a designated collec-

tion facility.

Contact your local recycling office

or your local distributor for further

information.

OM-223 839 Page 6

1 Warning! Watch Out! There

are possible hazards as

shown by the symbols.

2 Drive rolls can injure fingers

3 Welding wire and drive parts

are at welding voltage during

operation − keep hands and

metal objects away.

2 3

2-2. Symbols And Definitions

. Symbols found on product.

On Off Input Output

Amperes

Volts Alternating Current

Duty Cycle

Degree Of

Protection

Hertz Circuit Breaker Wire Feed

Read Instructions

Primary Voltage

Gas Metal Arc

Welding (GMAW)

Line Connection

Purge Remote

Water (Coolant)

Input

Water (Coolant)

Output

Conventional

Load Voltage

Primary Current

Rated Welding

Current

. Symbols not shown here are detailed in this manual when they are relevant.

OM-223 839 Page 7

SECTION 3 − INTRODUCTION

3-1. Important Information Regarding CE Products (Sold Within The EU)

! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.

This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public

access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding

circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure

information.

S The EMF assessment on this equipment was conducted at 0.5 meter.

S At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.

3-2. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the back . Use rating label to determine input power requirements and/or rated

output. For future reference, write serial number in space provided on back cover of this manual.

3-3. Specifications

Type of Input

Power

Welding Power

Source Type

Wire Feed

Speed Range

Wire Diameter

Range

Welding

Circuit Rating

IP Rating

Overall

Dimensions

Weight

24 Volts AC

Single-Phase

7 Amperes

50/60 Hertz

XMS 403 Welding

Power Source

0.5 − 20 m/min

0.8 mm − 1.8 mm

Max Spool Weight:

15 kg

36 Volts,

400 Amperes,

30% Duty

Cycle

IP23S

Length: 640 mm

Width: 230 mm

Height: 435 mm

18 kg

3-4. Remote 7 Receptacle Information

Remote 7

Pin Pin Information

1 +10 volts DC supply voltage to remote control

2 GND Remote control circuit common

3 IREF 0 to 10 current control signal

4 VREF 0 to 10 voltage control signal

5 UP 0V/10V digital signal

6 DOWN 0V/10V digital signal

7 TYPE 0V/10V digital signal

. This remote receptacle cannot be used with a standard Miller remote control. A customer supplied remote control is required to use the remote

receptacle.

OM-223 839 Page 8

3-5. 14-Pin Plug Information

Pin* Pin Information

A 24 volts AC with respect to socket G. Protected by circuit breaker CB1.

B GND of communciation signals.

C Serial communciation signal −485.

D Serial communication signal +485.

E Start motor signal to XMS 44.

F Trigger switch signal to XMS 403.

G Circuit common for 24 volts AC circuit.

H Wire feeder speed signal to XMS 44.

*The remaining pins are not used.

Use the proper interconnecting cables (P/N 058 019 140−141−142) to connect the unit to the XMS 403.

OM-223 839 Page 9

1 Gun Securing Knob

2 Gun Block

3 Gun Outlet Wire Guide

Loosen knob, insert gun into block.

Position outlet wire guide as close

as possible to drive rolls without

touching. Tighten knob.

4 Gun Trigger Plug

5 Gun Trigger Receptacle

. Contact manufacturer for

equipment needed to connect

US Gun.

. Make cooling system connec-

tions as shown in Section 3-9.

3-6. Connecting Welding Gun

802 308

Euro

Gun

US Gun

1 Inlet Wire Guide

2 Intermediate Wire Guide

Install and secure inlet wire guide,

and intermediate wire guide.

3 Drive Roll (4)

Install drive rolls and turn drive roll

nut one click.

During maintenance intervals,

remove drive rolls, and clean

grooves using a wire brush. Check

general condition of drive rolls.

Aligning Wire Guide And Drive

Rolls:

View is from top of drive rolls

looking down with pressure assem-

bly open.

Turn screw in or out until drive roll

groove lines up with wire guide.

Close pressure roll assembly.

Repeat for remaining drive rolls un-

til all drive rolls line up with wire

guides as shown.

3-7. Installing Wire Guide And Drive Roll

802 310-A

Tools Needed:

3/8 in

Incorrect Alignment

Correct Alignment

1−2

OM-223 839 Page 10

3-8. Circuit Protection

1 Circuit Breaker CB1

Circuit breaker CB1 is located in-

side the wire feeder as shown.

CB1 Protects the auxiliary 24 volt

AC circuit from overload.

3-9. Connecting Wire Feeder to Power Source

Make connections as shown. Be

sure connections are tight.

1 14 Pin Control Cord

2 Weld Cable (see Section 3-10

for connection inside wire

feeder)

3 Gas Hose

Connect hose to feeder using sup-

plied clamp. Connect other end of

gas hose to the power source gas

cylinder or gas circuit.

4 Blue Quick Connect Fitting

(Coolant Output to Gun)

Connect blue to blue and red to red.

5 Red Quick Connect Fitting

(Coolant Return From Gun)

Connect blue to blue and red to red.

6 Work Cable Clamp (see

Section 3-10)

7 Cable Bundle Collar (see

Section 3-10)

OM-223 839 Page 11

3-10. Changing Cable Between Wire Feeder and XMS 403

! Disconnect power before

changing cables.

1 Access Door

2 Clamp

3 Plastic Collar

Connect weld cable to terminals be-

hind access door.

Remove screws securing door,

clamp and collar. Make cable con-

nections. Reinstall clamp, collar,

and door.

Tools Needed:

3-11. Installing Wheels On Wire Feeder (Optional)

1 Bar

2 Nut

3 Wheels

4 Screws

Remove rubber feet from wire feeder.

Install only wheels on feeder if smaller

dimensions are desired, unit will be

used on level floors, or if optional turn-

table is used.

Install wheels and bars for increased

stability on uneven floors.

Tools Needed:

OM-223 839 Page 12

SECTION 4 − OPERATION

4-1. Control Panel

1 MIG Gun Connector

2 Red Quick Connect Fitting (Coolant

Return From Gun).

3 Blue Quick Connect Fitting (Coolant

Output To Torch)

4 Remote Control Receptacle

5 Handle

6 Panel

7 D1 − (Display 1)

Displays values and parameters for selected

welding process.

8 D2 − (Display 2)

Displays values and parameters for selected

welding process.

9 E1 (Encoder Control 1)

Use control to change values and parameters

that appear on D1.

10 E2 (Encoder Control 2)

Use control to change values and parameters

that appear on D2.

11 P1 (Trigger Selection Push Button)

Allows selecting desired trigger mode.

12 P2 (Memory/Setup Push Button)

Allows selecting Memory and Setup menus for

MIG welding.

13 P8 (Jog/Purge Push Button)

Performs jog and purge operations.

14 L1 ON means that D1 shows the voltage

value

15 L2 ON means that D1 shows the Trim

value

16 L3 ON means that D2 shows Wire Speed

value

17 L4 ON means that D2 shows Amperage

value

18 L5 ON means that D2 shows Material

Thickness value

19 L6 selection is Manual MIG welding

20 L7 selection is Synergic MIG welding

21 L8 selection is Synergic Pulsed MIG

welding

22 L9 selection is Synergic Double Pulsed

MIG welding

23 L10 ON selects 2 times trigger function

24 L11 ON selects 4 times trigger function

25 L12 ON selects 3 levels trigger function

26 L13 ON selects Setup menu

27 L14 On selects Memory menu

28 L15 ON selects Jog function

29 L16 ON selects Purge function

16 17 18

587

OM-223 839 Page 13

4-2. Switching On Unit And Recalling Factory Parameters

Install power source and wire feeder ac-

cording to supplied Owner’s Manuals. Turn

On welding power source.

Displays D1 and D2 will show the wire

feeder software version. Welding system is

ready to weld with the factory-set default

values, or the values and parameters of the

last weld.

When Stick or TIG welding, the wire feeder

is energized but does not work. Displays

D1 and D2 will show hyphens. When MIG

welding, wire feeder is always on. Displays

D1 and D2 will show set voltage and wire

speed (or correlated parameters), and the

measured welding voltage and current

while welding.

To recall factory-set parameters:

. Write down any parameters that need

to be restored before performing this

procedure.

Turn power source Off then On again. Im-

mediately press wire feeder P1 and P3. Re-

lease P1 and P3 when MEM CLR appears

on D1 and D2. Turn power source Off when

DON appears on D1. All parameters will re-

turn to factory default settings the next time

unit is turned on.

4-3. Welding Process Selection

MIG welding selection is made on the pow-

er source. Wire Feeder shows the welding

process selected with four LED’s.

Values and parameters that appear on D1

and D2 are either factory default settings or

last settings entered for the selected pro-

cess.

L6 selection is Manual MIG welding. See

Section 4-9.

D1 value is welding voltage; default is 18.5

volts (range is 10 to 50 volts).

D2 value is wire feed speed; default is 5

m/min (range is 1 m/min to 20 m/min).

L7 selection is Synergic MIG welding (non-

pulsed). See Section 4-10.

D1 value is trim, default is 0.0 T (range is

−5.0 T to 5.0 T).

D2 value is wire feed speed (from min to

max value according to welding curve

selection).

. When L7 is flashing, material transfer

in the arc is by large droplets (globular

transfer) and produces considerable

spatter. This is the result of selecting a

specific material, wire, gas, voltage,

and current combination. To avoid this

situation, Synergic Pulsed MIG weld-

ing with the same parameter combina-

tion is recommended. When L7 is On

continuously (not flashing), material

transfer in the arc is either short circuit

(Short Arc) or by small droplets (Spray

Transfer). Both MIG processes pro-

vide a stable arc and minimum spatter.

L8 selection is Synergic Pulsed MIG weld-

ing. See Section 4-12.

D1 value is Trim, default is 0.0 (range is

−5.0 to 5.0).

D2 value is wire feed speed (from minimum

to maximum value according to welding

curve selection).

L9 selection is Synergic Double Pulsed

MIG welding. See Section 4-12.

D1 value is trim, default is 0.0 (range is −5

to 5).

D2 value is wire feed speed (from min to

max value according to welding curve

selection).

OM-223 839 Page 14

4-4. Trigger Mode Selection

. Always check and set a trigger mode.

If trigger mode is undefined for a weld-

ing process, select the desired mode.

Trigger mode can be set for Manual MIG,

Synergic MIG, Synergic Pulsed MIG, and

Synegic Double Pulsed MIG welding to

change when output power is present at

the weld connectors. In Manual MIG, Syn-

ergic MIG, Synergic Pulsed MIG, and Syn-

ergic Double Pulsed MIG welding, press-

ing P1 will change trigger mode, but D1 and

D2 will not change values.

Press P1 to select the desired trigger

mode:

L10 ON selects 2 times trigger function.

When trigger is pressed, welding starts.

When trigger is released, welding stops.

L11 ON selects 4 times trigger function.

When trigger is pressed, welding starts.

When trigger is released, welding contin-

ues.

When trigger is pressed and released a

second time, welding stops.

L12 ON selects 3 levels trigger function.

When trigger is pressed, welding starts

with level 1 parameters.

When trigger is released, welding contin-

ues with main parameters.

When trigger is pressed a second time,

welding continues at level 2 parameters.

When trigger is released the second time,

welding stops.

L12 trigger mode is useful for aluminum

and for a crater fill sequence.

In Manual MIG process, 2 times and 4

times trigger mode can be selected.

In Synergic MIG process, 2 times, 4 times

and 3 levels can be selected.

In Synergic Pulsed MIG process, 2 times,

4 times, and 3 levels can be selected.

In Synergic Double Pulsed MIG process, 2

times, 4 times, and 3 levels can be se-

lected.

L10

L11

L12

4-5. Setup Menu and Memory Menu Selection

L13 and L14 are generally OFF.

P2 selects the Setup Menu and the ad-

vance programming of MIG welding and to

memorize and manage personal welding

parameters in MIG welding.

Press P2 to select Setup Menu. L13 is ON.

Press P2 a second time to select Memory

Menu. L14 is ON.

Press P2 again to exit Setup and Memory

Menu. L13 and L14 are OFF.

In order to complete Setup and/or Memory

procedures you have to exit these menus.

L13 and L14 must be off.

. In Setup Menu and Memory Menu you

cannot weld. This avoids setting er-

rors in the welding parameters and in

the memorized welding parameters.

L13

L14

OM-223 839 Page 15

4-6. Setup Menu

Press P2 to enter SET UP menu.

Setup allows viewing and changing default

parameter values for all welding processes

for the desired weld characteristics.

D1 shows the welding parameter.

D2 shows the parameter value.

E1 changes the welding parameter.

E2 changes the parameter value.

P2 allows to exit setup Menu and Ad-

vanced Programming and to save the

changed parameters.

. Incorrect settings in any process can

result in a program with undesirable

weld characteristics. Setup should

only be used by operators familiar with

various welding processes and pa-

rameters.

4-7. Memory Menu

Press P2 to enter Memory menu.

D1 shows the first free memory position or

the last memory used.

E1 changes the memory position number

from P.01 to P.99.

Any memory position contains all the se-

lected MIG welding parameters in the Wire

Feeder and in the Power Source.

When a memorized welding point is loaded

the Wire Feeder and the Power Source is

set accordingly.

Verify the Power Source status before

welding, if needed.

D1 shows the memory position.

E1 changes the memory position.

D2 shows the action you can perform on

the memory position.

E2 changes the action on the memory posi-

tion.

When D2 shows Ld (load), you can load in

the welder the parameters in the memory

position selected by D1.

When D2 shows Sto (storage), you can

memorize the actual welding parameters in

the memory position selected by D1.

When D2 shows dEL (delete), you can de-

lete the parameters memorized in the

memory position selected by D1.

In order to confirm the action, press P2 until

D1 and D2 flash.

Release P2 and wait until flashing stops.

The action is now performed and the weld-

er exits the Memory menu.

. Do not perform any operation on the

welder when in Memory menu to pre-

vent incorrect weld parameters and

poor operation.

4-8. Jog And Purge Selection

. If a function is selected and not used

within several seconds, the LED will

turn off .

To use the jog and purge function, proceed

as follows:

Pressing P3 once selects jog. Pressing P8

a second time selects purge.

When L15 illuminates, press and hold P3 to

perform jog function.

Jog feeds welding wire without weld output

power applied to the wire.

In Jog mode, D1 shows JOG and D2

shows wire feed speed.

Use E2 to change wire feed speed setting.

. Jog will be performed if gun trigger is

pressed and held without striking a

welding arc. Front panel Jog is recom-

mended.

When L16 illuminates, press and hold P3 to

perform purge function.

. Purge is used to remove impurities and

fill the gas hose with shielding gas.

Pre−Gas is a similar function, but only

operates at the beginning of a welding

process. Purge can be performed in

the TIG process by pressing the torch

trigger without striking an arc.

L15

L16

OM-223 839 Page 16

4-9. Preparing Unit For MIG Welding

To select MIG welding process, pro-

ceed as follows:

Follow safety precautions according to

Section 1.

Prepare unit according to Section 3.

1 Using a cable with a proper

adapter, connect gun to the MIG

gun connector.

Connect work clamp cable to the

WORK connector on the power source.

2 If using a water-cooled gun,

connect input coolant hose to blue

quick connect fitting

3 Connect return coolant hose to

red quick connect fitting.

Check coolant level after attaching

torch coolant hoses and running cooler.

Be sure coolant appears in upper half of

indicator. Add coolant if necessary (see

Power Source manual).

4 If a remote control is desired,

connect it to the Remote Control

receptacle

Turn unit On.

Allow time for unit to complete its start

up cycle.

Set MIG welding process on the Power

Source and check L1, L2, L3 and L4 on

the Wire Feeder.

Purge air from the gas hose using P3

pushbutton (see Section 4-8).

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Miller 242780 Owner's manual

Brand: Miller

Model: 242780

Category: Welding System

Type: Owner's manual

This manual is also suitable for

XMS 44

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Miller 242780 Owner's manual

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Miller 242780 Owner's manual

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